Methods and systems for increasing airflow through a charge air cooler to decrease charge air cooler condensate

ABSTRACT

Methods and systems are provided for increasing airflow through a charge air cooler (CAC) in order to purge condensate from the CAC. In one example, a method includes increasing airflow through the CAC while maintaining torque by selectively deactivating one or more engine cylinders and increasing boost. The number of deactivated cylinders may be based on an amount of condensate within the CAC.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 14/295,176, entitled “METHODS AND SYSTEMS FOR INCREASINGAIRFLOW THROUGH A CHARGE AIR COOLER TO DECREASE CHARGE AIR COOLERCONDENSATE,” filed on Jun. 3, 2014, the entire contents of which arehereby incorporated by reference for all purposes.

FIELD

The present description relates generally to methods and systems forcontrolling a vehicle engine to decrease condensate formation within acharge air cooler.

BACKGROUND/SUMMARY

Engines may utilize a turbocharger or supercharger to compress ambientair entering the engine in order to increase power. Compression of theair may cause an increase in air temperature, thus, an intercooler orcharge air cooler (CAC) may be utilized to cool the heated air therebyincreasing its density and further increasing the potential power of theengine. Condensate may form in the CAC when the ambient air temperaturedecreases, or during humid or rainy weather conditions, where the intakeair is cooled below the water dew point temperature. Further, when thecharge air entering the CAC is boosted (e.g., an induction pressure andboost pressure are greater than atmospheric pressure), condensate mayform if the CAC temperature falls below the dew point temperature. As aresult, condensate may collect at the bottom of the CAC, or in theinternal passages of the CAC. When torque is increased, such as duringacceleration, increased mass air flow may strip the condensate from theCAC, drawing it into the engine and increasing the likelihood of enginemisfire and combustion instability.

Other attempts to address engine misfire due to condensate ingestioninvolve avoiding condensate build-up. However, the inventors herein haverecognized potential issues with such methods. Specifically, while somemethods may reduce or slow condensate formation in the CAC, condensatemay still build up over time. If this build-up cannot be stopped,ingestion of the condensate during acceleration may cause enginemisfire. Another method to prevent engine misfire due to condensateingestion includes trapping and/or draining the condensate from the CAC.While this may reduce condensate levels in the CAC, condensate is movedto an alternate location or reservoir, which may be subject to othercondensate problems such as freezing and corrosion.

Condensate build-up in the CAC may also be addressed by removingcondensate from the CAC before it builds up to a threshold level byincreasing airflow through the CAC. For example, as shown in2014/0048048, adjusting a valve positioned in an inlet tank of avariable volume CAC may adjust the airflow rate through the CAC.Increased airflow through the CAC may reduce condensate build-up in theCAC. However, the inventors herein have recognized potential issues withsuch systems. As one example, a variable volume CAC may requireadditional parts and controls for controlling airflow through the CAC.

In one example, the issues described above may be addressed by a methodfor transiently increasing airflow through a charge air cooler (CAC) ofthe engine by one or more of operating in a VDE mode or opening acompressor bypass valve (CBV) and maintaining engine torque byincreasing boost pressure. In this way, the increased airflow may purgecondensate from the CAC and reduce engine misfire events and/or unstablecombustion due to ingestion of large amounts of condensate by theengine.

As one example, an engine controller may increase airflow through theCAC by one or more of operating the engine in the VDE mode or openingthe CBV while increasing boost to maintain torque in response to acondensate level of the CAC increasing above a threshold level.

In one example, operating in the VDE mode includes selectivelydeactivating a number of engine cylinders, the number of enginecylinders based on the condensate level. The selectively deactivatingthe number of engine cylinders includes deactivating fueling to thedeactivated cylinders while maintaining intake and exhaust valveoperation. In another example, the CBV may be arranged in a bypasspassage positioned between an intake passage downstream of the CAC andthe intake passage upstream of a compressor. As such, opening the CBVrecirculates air around the CAC and the compressor, thereby increasingairflow through the CAC. In an alternate example, the increasing CACairflow may be performed periodically at set intervals. In this way,condensate build-up may be reduced, thereby reducing engine misfireevents.

It should be understood that the summary above is provided to introducein simplified form a selection of concepts that are further described inthe detailed description. It is not meant to identify key or essentialfeatures of the claimed subject matter, the scope of which is defineduniquely by the claims that follow the detailed description.Furthermore, the claimed subject matter is not limited toimplementations that solve any disadvantages noted above or in any partof this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an example engine system including acharge air cooler.

FIG. 2 shows a flow chart of a method for operating an engine in VDEmode.

FIG. 3 shows a flow chart of a method for operating a compressor bypassvalve.

FIG. 4 shows a flow chart of a method for increasing airflow through acharge air cooler to purge condensate from the charge air cooler.

FIG. 5 shows a flow chart of a method for inferring a condensate levelat the charge air cooler.

FIG. 6 shows a flow chart of a method for increasing airflow through acharge air cooler to purge condensate from the charge air cooler byopening a compressor bypass valve while increasing boost.

FIG. 7 shows a flow chart of a method for increasing airflow through acharge air cooler to purge condensate from the charge air cooler bydeactivating one or more engine cylinders while increasing boost.

FIG. 8 is a graph of example adjustments to engine operating parametersto increase airflow through a charge air cooler responsive to charge aircooler condensate.

DETAILED DESCRIPTION

The following description relates to systems and methods for increasingairflow through a charge air cooler (CAC), such as the CAC shown in FIG.1, in order to remove condensate from the CAC and reduce condensatebuild-up. An engine system, such as the engine system shown in FIG. 1,may be capable of operating in a VDE mode wherein one or more enginecylinders may be selectively deactivated. The engine system may alsoinclude a bypass passage including a compressor bypass valve (CBV)around both the CAC and compressor. Methods for operating the engine ina VDE mode and operating the CBV are shown in FIG. 2 and FIG. 3,respectively. In response to condensate build-up in the CAC, an enginecontroller may increase airflow through the CAC to purge condensate fromthe CAC. FIG. 4 shows a method for increasing airflow through the CAC byeither opening the CBV or operating the engine in VDE mode based onengine operating conditions. FIG. 5 shows a method for determining thecondensate level in the CAC. A method for increasing airflow through theCAC by opening the CBV while increasing boost is shown at FIG. 6.Similarly, FIG. 7 shows a method for increasing airflow through the CACby deactivating one or more engine cylinders while increasing boost.FIG. 8 shows example adjustments to the CBV, VDE operation, andadditional engine operating conditions based on CAC condensate.

FIG. 1 is a schematic diagram showing an example engine 10, which may beincluded in a propulsion system of an automobile. The engine 10 is shownwith four cylinders or combustion chambers 30. However, other numbers ofcylinders may be used in accordance with the current disclosure. Inanother example, the engine 10 may be a V-engine with two banks ofcylinders 30. Engine 10 may be controlled at least partially by acontrol system including a controller 12, and by input from a vehicleoperator 132 via an input device 130. In this example, the input device130 includes an accelerator pedal and a pedal position sensor 134 forgenerating a proportional pedal position signal PP. Each combustionchamber (e.g., cylinder) 30 of the engine 10 may include combustionchamber walls with a piston (not shown) positioned therein. The pistonsmay be coupled to a crankshaft 40 so that reciprocating motion of thepiston is translated into rotational motion of the crankshaft. Thecrankshaft 40 may be coupled to at least one drive wheel of a vehiclevia an intermediate transmission system 150. Further, a starter motormay be coupled to crankshaft 40 via a flywheel to enable a startingoperation of engine 10. The crankshaft 40 may also be used to drive analternator (not shown in FIG. 1).

An engine output torque may be transmitted to a torque converter (notshown) to drive the automatic transmission system 150. Further, one ormore clutches may be engaged, including forward clutch 154, to propelthe automobile. In one example, the torque converter may be referred toas a component of the transmission system 150. Further, transmissionsystem 150 may include a plurality of gear clutches 152 that may beengaged as needed to activate a plurality of fixed transmission gearratios. Specifically, by adjusting the engagement of the plurality ofgear clutches 152, the transmission may be shifted between a higher gear(that is, a gear with a lower gear ratio) and a lower gear (that is, agear with a higher gear ratio). As such, the gear ratio differenceenables a lower torque multiplication across the transmission when inthe higher gear while enabling a higher torque multiplication across thetransmission when in the lower gear. The vehicle may have four availablegears, where transmission gear four (transmission fourth gear) is thehighest available gear and transmission gear one (transmission firstgear) is the lowest available gear. In other embodiments, the vehiclemay have more or less than four available gears. As elaborated herein, acontroller may vary the transmission gear (e.g., upshift or downshiftthe transmission gear) to adjust an amount of torque conveyed across thetransmission and torque converter to vehicle wheels 156 (that is, anengine shaft output torque). As the transmission shifts to a lower gear,the engine speed (Ne or RPM) increases, increasing engine airflow. Anintake manifold vacuum generated by the spinning engine may be increasedat the higher RPM.

The combustion chambers 30 may receive intake air from the intakemanifold 44 and may exhaust combustion gases via an exhaust manifold 46to an exhaust passage 48. The intake manifold 44 and the exhaustmanifold 46 can selectively communicate with the combustion chamber 30via respective intake valves and exhaust valves (not shown). In someembodiments, the combustion chamber 30 may include two or more intakevalves and/or two or more exhaust valves.

Fuel injectors 50 are shown coupled directly to the combustion chamber30 for injecting fuel directly therein in proportion to the pulse widthof signal FPW received from controller 12. In this manner, the fuelinjector 50 provides what is known as direct injection of fuel into thecombustion chamber 30; however it will be appreciated that portinjection is also possible. Fuel may be delivered to the fuel injector50 by a fuel system (not shown) including a fuel tank, a fuel pump, anda fuel rail.

In a process referred to as ignition, the injected fuel is ignited byknown ignition means such as spark plug 52, resulting in combustion.Spark ignition timing may be controlled such that the spark occursbefore (advanced) or after (retarded) the manufacturer's specified time.For example, spark timing may be retarded from maximum break torque(MBT) timing to control engine knock or advanced under high humidityconditions. In particular, MBT may be advanced to account for the slowburn rate. In one example, spark may be retarded during a tip-in. In analternate embodiment, compression ignition may be used to ignite theinjected fuel.

The intake manifold 44 may receive intake air from an intake passage 42.An engine intake of the engine 10 includes the intake manifold 44 andthe intake passage 42. The intake passage 42 and/or intake manifold 44includes a throttle 21 having a throttle plate 22 to regulate flow tothe intake manifold 44. In this particular example, the position (TP) ofthe throttle plate 22 may be varied by the controller 12 to enableelectronic throttle control (ETC). In this manner, the throttle 21 maybe operated to vary the intake air provided to the combustion chambers30. For example, the controller 12 may adjust the throttle plate 22 toincrease an opening of the throttle 21. Increasing the opening of thethrottle 21 may increase the amount of air supplied to the intakemanifold 44. In an alternate example, the opening of the throttle 21 maybe decreased or closed completely to shut off airflow to the intakemanifold 44.

In some embodiments, additional throttles may be present in intakepassage 42, such as a throttle upstream of a compressor 60 (not shown).Additionally, the throttle position or throttle angle of the throttle 21may be determined with a throttle position sensor 23 positioned at thethrottle 21. In one example, the throttle position sensor 23 may measurethe angle of the throttle plate 22 relative to the direction of air flowthrough the intake passage 42. For example, when the throttle plate 22is completely closed (and blocking airflow through the intake passage42), the throttle angle may be approximately zero degrees. When thethrottle plate 22 is completely open (and perpendicular to airflow) thethrottle angle may be approximately 90 degrees.

Further, in the disclosed embodiments, an exhaust gas recirculation(EGR) system may route a desired portion of exhaust gas from the exhaustpassage 48 to the intake passage 42 via an EGR passage, such as highpressure EGR passage 140. The amount of EGR provided to the intakepassage 42 may be varied by the controller 12 via an EGR valve, such ashigh pressure EGR valve 142. Under some conditions, the EGR system maybe used to regulate the temperature of the air and fuel mixture withinthe combustion chamber. FIG. 1 shows a high pressure EGR system whereEGR is routed from upstream of a turbine of a turbocharger to downstreamof a compressor of a turbocharger through EGR passage 140. FIG. 1 alsoshows a low pressure EGR system where EGR is routed from downstream ofturbine of a turbocharger to upstream of a compressor of a turbochargerthrough low pressure EGR passage 157. A low pressure EGR valve 155 maycontrol the amount of EGR provided to the intake passage 42. In someembodiments, the engine may include both a high pressure EGR and a lowpressure EGR system, as shown in FIG. 1. In other embodiments, theengine may include either a low pressure EGR system or a high pressureEGR system. When operable, the EGR system may induce the formation ofcondensate from the compressed air, particularly when the compressed airis cooled by the charge air cooler 80. For example, the low pressure EGRpassage 157 may include a low pressure EGR cooler 159 and the highpressure EGR passage 140 may include a high pressure EGR cooler 143.

The engine 10 may further include a compression device such as aturbocharger or supercharger including at least a compressor 60 arrangedalong the intake passage 42. For a turbocharger, the compressor 60 maybe at least partially driven by a turbine 62, via, for example a shaft,or other coupling arrangement. The turbine 62 may be arranged along theexhaust passage 48. Various arrangements may be provided to drive thecompressor. For a supercharger, the compressor 60 may be at leastpartially driven by the engine and/or an electric machine, and may notinclude a turbine. Thus, the amount of compression provided to one ormore cylinders of the engine via a turbocharger or supercharger may bevaried by the controller 12. For example, as shown in FIG. 1, the engine10 may include an electric turbocharger assist device 65. The electricturbocharger assist device 65 may be chargeable and then provide powerto the compressor 60 when increased boost is required. As such, theelectric turbocharger assist device may enable the compressor 60 toreach a desired rotational speed for delivering required boost morequickly than if the turbine 62 alone was providing driving power to thecompressor 60. In another example, the compressor 60 may be drivenprimarily by the turbine 62. The turbine 62 may be driven by exhaustgases flowing through the exhaust passage 48. Thus, the driving motionof the turbine 62 may drive the compressor 60. As such, the speed of thecompressor 60 may be based on the speed of the turbine 62. As the speedof the compressor 60 increases, more boost may be provided through theintake passage 42 to the intake manifold 44.

Further, the exhaust passage 48 may include a wastegate 26 for divertingexhaust gas away from the turbine 62. Additionally, the intake passage42 may include a compressor bypass valve (CBV) 27 configured to divertintake air around the compressor 60. As shown in FIG. 1, the CBV 27 maybe positioned in a bypass passage 29 bypassing the compressor 60 and theCAC 80. Specifically, an air inlet to the bypass passage 29 may bedownstream of the CAC 80 and an air outlet from the bypass passage 29and to the intake passage 42 may be upstream of the compressor 60. Assuch, when the CBV 27 is opened, charge air may be diverted fromdownstream of the CAC 80 to upstream of the compressor 60. The wastegate26 and/or the CBV 27 may be controlled by the controller 12 to be openedwhen a lower boost pressure is desired, for example. For example, inresponse to compressor surge or a potential compressor surge event, thecontroller 12 may open the CBV 27 to decrease pressure at the outlet ofthe compressor 60. This may reduce or stop compressor surge.

The intake passage 42 may further include the charge air cooler (CAC) 80(e.g., an intercooler) to decrease the temperature of the turbochargedor supercharged intake gases. In some embodiments, the CAC 80 may be anair to air heat exchanger. In other embodiments, the CAC 80 may be anair to liquid heat exchanger. The CAC 80 may also be a variable volumeCAC. Hot charge air (boosted air) from the compressor 60 enters theinlet of the CAC 80, cools as it travels through the CAC, and then exitsto pass through the throttle 21 and then enter the engine intakemanifold 44. Ambient air flow from outside the vehicle may enter engine10 through a vehicle front end and pass across the CAC, to aid incooling the charge air. Condensate may form and accumulate in the CACwhen the ambient air temperature decreases, or during humid or rainyweather conditions, where the charge air is cooled below the water dewpoint temperature. Further, when the charge air entering the CAC isboosted (e.g., boost pressure and/or CAC pressure is greater thanatmospheric pressure), condensate may form if the CAC temperature fallsbelow the dew point temperature. When the charge air includesrecirculated exhaust gasses, the condensate can become acidic andcorrode the CAC housing. The corrosion can lead to leaks between the aircharge, the atmosphere, and possibly the coolant in the case ofwater-to-air coolers. Further, if condensate builds up in the CAC, itmay be ingested by the engine during times of increased airflow. As aresult, unstable combustion and/or engine misfire may occur. The engine10 may further include one or more oxygen sensors positioned in theintake passage 42 and/or the intake manifold 44.

The intake manifold 44 includes a MAP sensor 122 for measuring anabsolute manifold pressure (MAP). As discussed further below, the outputof the MAP sensor 122 may be used to estimate other engine systempressures such as BP. In some embodiments, the intake passage 42 mayinclude a boost pressure sensor 126. However, in other embodiments, theintake passage may not include the boost pressure sensor 126.Additionally, a mass air flow (MAF) sensor 120 may be positioned in theintake passage 42, upstream of the compressor 60.

The controller 12 is shown in FIG. 1 as a microcomputer, includingmicroprocessor unit 102, input/output ports 104, an electronic storagemedium for executable programs and calibration values shown as read onlymemory chip 106 in this particular example, random access memory 108,keep alive memory 110, and a data bus. The controller 12 may receivevarious signals from sensors coupled to the engine 10 for performingvarious functions to operate the engine 10. In addition to those signalspreviously discussed, these signals may include measurement of inductedmass air flow from the MAF sensor 120; engine coolant temperature (ECT)from temperature sensor 112, shown schematically in one location withinthe engine 10; a profile ignition pickup signal (PIP) from Hall effectsensor 118 (or other type) coupled to crankshaft 40; the throttleposition (TP) from a throttle position sensor, as discussed; andabsolute manifold pressure signal, MAP, from sensor 122, as discussed.Engine speed signal, RPM, may be generated by the controller 12 fromsignal PIP. Manifold pressure signal MAP from a manifold pressure sensormay be used to provide an indication of vacuum, or pressure, in theintake manifold 44. Note that various combinations of the above sensorsmay be used, such as a MAF sensor without a MAP sensor, or vice versa.The MAP sensor can give an indication of engine torque. Further, thissensor, along with the detected engine speed, can provide an estimate ofcharge (including air) inducted into the cylinder. In one example, theHall effect sensor 118, which is also used as an engine speed sensor,may produce a predetermined number of equally spaced pulses everyrevolution of the crankshaft 40.

Other sensors not depicted may also be present, such as a sensor fordetermining ambient air temperature and/or humidity, and other sensors.In some examples, storage medium read-only memory chip 106 may beprogrammed with computer readable data representing instructionsexecutable by microprocessor unit 102 for performing the methodsdescribed below as well as other variants that are anticipated but notspecifically listed. Example routines are described herein at FIGS. 2-5.

In one example, engine 10 may be a variable displacement engine (VDE)capable of operating in a VDE mode wherein one or more cylinders areselectively deactivated. For example, engine 10 may be a V-enginewherein combustion chambers 30 are arranged into a first bank ofcylinders and a second bank of cylinders. In another example, engine 10may be an in-line engine (as shown in FIG. 1) wherein one or morecylinders may be selectively deactivated (e.g., any number of cylindersmay be deactivated). As one example, during low engine loads when thefull torque capability of the engine is not needed, one or morecylinders 30 of the engine 10 (or of a selected engine bank) may beselectively deactivated (herein also referred to as a VDE mode ofoperation). This may include deactivating fuel and spark on the selectedengine cylinder(s) or cylinder bank. Specifically, one or more cylindersor one or more cylinders of the selected group of cylinders may bedeactivated by shutting off respective fuel injectors while maintainingoperation of the intake and exhaust valves such that air may continue tobe pumped through the cylinders. While fuel injectors of the disabledcylinders are turned off, the remaining enabled cylinders continue tocarry out combustion with fuel injectors active and operating. To meetthe torque requirements, the engine produces the same amount of torqueon those cylinders for which the injectors remain enabled. This requireshigher manifold pressures, resulting in lowered pumping losses andincreased engine efficiency. Also, the lower effective surface area(from only the enabled cylinders) exposed to combustion reduces engineheat losses, improving the thermal efficiency of the engine. In oneexample, an engine controller may selectively deactivate all thecylinders of a given engine bank during shift to a VDE mode and thenreactivate the cylinders during a shift back to a non-VDE mode. Inanother example, the controller may selectively deactivate a subset of atotal number of engine cylinders 10 during VDE mode. During thedeactivation, the controller may increase boost, thereby increase themanifold pressure and allowing the active engine cylinders to deliverthe required torque.

The system of FIG. 1 provides for an engine system including an intakepassage including an intake throttle, a turbocharger including acompressor at least partially driven by an exhaust-driven turbine, acharge air cooler (CAC) positioned upstream of the throttle anddownstream of the compressor, and a compressor bypass valve (CBV)positioned in a bypass passage coupled between the intake passagedownstream of the CAC and the intake passage upstream of the compressor.The system further includes a controller with computer readableinstructions for transiently increasing airflow through the CAC by oneor more of selectively deactivating one or more cylinders of the engineor opening the CBV responsive to condensate formation in the CAC andmaintaining engine torque by increasing boost pressure. The systemfurther includes an electric machine coupled to the turbocharger, theelectric machine providing rotative power to the compressor to increaseboost pressure. The engine may be a variable displacement engine (VDE)where selectively deactivating one or more cylinders of the engineincludes operating in a VDE mode. Additionally, selectively deactivatingone or more cylinders of the engine includes disabling fueling to theone or more deactivated cylinders while maintaining operation of allcylinder intake and exhaust valves.

As discussed above, condensate may form within a charge air cooler(CAC). Over time, condensate may accumulate within the CAC, therebyresulting in an increasing level (or amount) of condensate within theCAC. During conditions of increased airflow through the CAC (such asduring a tip-in), condensate may be blown out of the CAC and enter theengine. In some cases, this may cause unstable combustion and/or enginemisfire. In one example, reducing condensate build-up within the CAC mayreduce engine misfire and/or unstable combustion events. Condensatebuild-up may be reduced by periodically and/or opportunistically purgingcondensate from the CAC by increasing airflow through the CAC.Increasing airflow through the CAC may include increasing an amount ofairflow or an airflow rate (e.g., mass air flow rate) through the CAC.As airflow through the CAC increases, condensate may be stripped fromthe cooling tubes and carried out of the CAC and into the charge airflow to the intake manifold. The purging of condensate from the CAC mayoccur before condensate has built-up to a threshold level within theCAC, the threshold level being an amount of condensate that may causeunstable combustion and/or misfire if ingested at once by the engine.The controller of the engine may initiate a condensate purging cycleperiodically (as a preventative action), when condensate-formingconditions are present (e.g., increased humidity and/or decreased CACtemperature), or when the CAC condensate level increases above athreshold level.

The controller may increase airflow through the CAC to remove condensatefrom the CAC using various methods. However, in order to maintain torqueduring the increase in airflow, the controller may need to adjustadditional engine operating parameters. For example, increasing airflowthrough the CAC also increases airflow (e.g., mass air flow) to theengine, thereby increasing torque if no other adjustments are made. Inorder to maintain torque, compensating actions may be taken to reducetorque in order to deliver the demanded torque. In one example, thecontroller may open a compressor bypass valve (CBV) arranged in a bypasspassage around the compressor and CAC while also increasing boost (e.g.,boost pressure) in order to increase airflow through the CAC to reducecondensate build-up while also maintaining the demanded torque. Asdiscussed above, opening the CBV in the bypass passage may divert airfrom downstream of the CAC to upstream of the compressor. Opening theCBV may therefore increase the amount of air flowing through the CAC,thereby stripping condensate from the CAC and reducing condensatebuild-up within the CAC. By simultaneously increasing boost (e.g.,increasing the boost pressure delivered to the intake manifold by thecompressor), the MAP may be maintained at a desired level to deliver thetorque demand. Said another way, opening the CBV may increase airflowthrough the CAC while decreasing boost pressure and MAP and increasingboost may increase the boost pressure and MAP. By coordinating theincrease in boost generated by the compressor and the decrease in boostby opening the CBV, the engine may produce the demanded torque.

As described above, as the compressor rotates more quickly, more boostmay be generated. If the compressor is primarily driven by the turbine,the controller may adjust engine operation to increase exhaust flow,thereby increasing turbine speed and subsequently compressor speed.However, if the turbocharger is an electric turbocharger or anelectrically-assisted turbocharger, the electric machine coupled to theturbocharger may more quickly increase the speed of the compressor todeliver the increased boost pressure. Boost pressure and torque may alsobe adjusted by adjusting a position of the wastegate and/or throttle.

In another example, the controller may operate the engine in a VDE modewhile increasing boost in order to increase airflow through the CAC toreduce condensate build-up while also maintaining the demanded torque.As discussed above, engine operation in VDE mode may include selectivelydeactivating fueling to one or more cylinders of the engine whilemaintaining operation of the intake and exhaust valves of all the enginecylinders. As a result, the deactivated cylinders may not combust fuelor provide engine power, however they may continue to pump air. Thepumping of air through the deactivated cylinders increases airflowthrough the CAC, thereby stripping condensate from the CAC. Whenoperating in VDE mode, boost may be increased to increase the MAP sothat the active cylinders may deliver the demanded torque. As a result,an increase in total airflow through the engine may increase during VDEoperation so that the active cylinders may deliver the torque demand.

In this way, a method for an engine comprises transiently increasingairflow through a charge air cooler of the engine by one or more ofoperating in a VDE mode or opening a compressor bypass valve andmaintaining engine torque by increasing boost pressure. In one example,transiently increasing airflow through the charge air cooler (CAC) isperformed periodically when condensate forming conditions are present,the condensate forming conditions including one or more of an ambienthumidity over a threshold humidity, a CAC temperature below a thresholdtemperature, and an ambient temperature below a threshold temperature.In another example, the transiently increasing airflow through thecharge air cooler (CAC) is responsive to one or more of a condensatelevel or a condensate accumulation rate within the CAC over a threshold.

The method further comprises transiently increasing airflow through theCAC by operating in the VDE mode when the compressor bypass valve cannotbe opened and temporarily operating in the VDE mode is possible based onengine operating conditions. In one example, the engine operatingparameters may include torque demand below a threshold. Further, themethod comprises transiently increasing airflow through the CAC byopening the compressor bypass valve and not by operating in VDE modewhen the compressor bypass valve is able to be opened based on engineoperating conditions. The engine operating conditions may include acompressor surge condition and/or MAP greater than required to producethe torque demand.

Operating in VDE mode to increase airflow through the CAC includesselectively deactivating one or more cylinders of the engine bydisabling fueling to the one or more cylinders while maintainingoperation of cylinder intake and exhaust valves. Additionally, a numberof the one or more deactivated cylinders is based on a condensate levelin the CAC, the number of the one or more deactivated cylindersincreasing with increasing condensate level in the CAC. Opening thecompressor bypass valve (CBV) to increase airflow through the CACincludes opening the CBV to a percentage opening, the percentage openingincreasing with increasing condensate level in the CAC. The CBV ispositioned in a bypass passage positioned between an intake passagedownstream of the CAC and the intake passage upstream of a compressor ofthe engine. Further still, maintaining engine torque by increasing boostpressure includes one or more of increasing exhaust flow to a turbinedriving a compressor, closing a wastegate, and operating an electricturbocharger.

The method further comprises, stopping increasing airflow through theCAC by one or more of switching from VDE operation to non-VDE operationor closing the CBV responsive to a condensate level in the CACdecreasing below a threshold. In another example, the method comprisesstopping increasing airflow through the CAC by one or more of switchingfrom VDE operation to non-VDE operation or closing the CBV responsive toa torque demand over a threshold.

Turning now to FIG. 2, a method 200 is shown for operating an engine inVDE mode. For example, the method 200 may show normal VDE operationbased on engine operating conditions. Instructions for carrying outmethod 200 may be stored in a memory of a controller (such as controller12 shown in FIG. 1).

The method begins at 202 by estimating and/or measuring engine operatingconditions. Engine operating conditions may include engine speed/load,boost, torque demand, MAP, a number of active or deactivated cylinders,air-fuel ratio, MAF, conditions of a CAC (e.g., temperature, pressure,and condensate level), etc. The method at 202 may also includedetermining a current engine mode of operation, particularly with orwithout cylinder deactivation (e.g., VDE or non-VDE), and a desired modeof operation. For example, if the torque demand is low, the controllermay determine that one or more cylinders can be deactivated while thetorque demand is met by the remaining active cylinders. In comparison,if the torque demand is high, the controller may determine that all thecylinders need to remain active. In another example, all cylinders maybe deactivated if an engine idle-stop condition is met.

At 204, the method includes determining if VDE mode conditions are met.In one example, VDE mode (e.g., cylinder deactivation) conditions may beconfirmed when torque demand is less than a threshold. If VDE modeconditions are not confirmed, at 206, the method includes maintainingall the cylinders in an active mode undergoing combustion (e.g., engineis maintained in non-VDE mode). On the other hand, if VDE modeconditions are confirmed, at 208, the method may selectively deactivateone or more cylinders. Selectively deactivating cylinders at 208 mayinclude shutting off fueling to one or more cylinders while maintainingoperation of the exhaust and intake valves, the number of deactivatedcylinders based on engine operating conditions such as engine load. Inother embodiments, selectively deactivating cylinders may includedisabling fuel and the exhaust and intake valves to one or morecylinders.

At 210, the method includes determining if non-VDE conditions are met.In other words, the method at 210 determines if cylinder reactivationconditions are met. In one example, non-VDE conditions may be met whenthe engine torque demand increases above a threshold. In anotherexample, non-VDE conditions may be considered met when the engine hasoperated in the VDE mode for a specified duration. If non-VDE modeconditions are not met, at 212, the method continues to maintain engineoperation in VDE mode, thereby maintaining the deactivated cylinders intheir deactivated state. Else, at 214, the deactivated cylinders may bereactivated. In one example, reactivation may include the engine beingoperated in a non-VDE mode.

In some embodiments, the standard VDE operation shown in method 200 maybe overridden based on condensate conditions of the CAC. For example,even if VDE conditions are not met, the controller may switch the enginefrom a non-VDE mode to VDE mode if condensate formation in the CAC isover a threshold. In another example, standard VDE operation may beadjusted based on CAC condensate such that the number of deactivatedcylinders is based on a condensate level in the CAC. Further details onadjusting VDE operation based on CAC condensate are discussed below withreference to FIG. 4 and FIG. 7.

FIG. 3 shows a method 300 for operating a compressor bypass valve (CBV).In one example, the CBV valve is positioned in a bypass passagepositioned between an intake passage downstream of a CAC and the intakepassage upstream of a compressor (such as the bypass passage 29 and CBV27 shown in FIG. 1). As such, upon opening the CBV, air flow is routedfrom downstream of the compressor to upstream of the compressor. Openingthe CBV may result in increased airflow through the CAC. As discussedfurther below, opening the CBV may be based on compressor surgeconditions under standard operation of the CBV. Instructions forcarrying out method 300 may be stored in a memory of a controller (suchas controller 12 shown in FIG. 1). As such, method 300 may be executedby the controller.

Method 300 begins by estimating and/or measuring engine operatingconditions. Engine operating conditions may include engine speed and/orload, torque demand, MAP, MAF, boost, etc. At 304, the method includesdetermining if compressor surge conditions are present. Compressor surgeconditions may be based on boost pressure, MAP, and/or MAF. Compressorsurge conditions may include compressor surge being imminent based onengine operating conditions and/or compressor surge itself. If surgeconditions are not present, the method continues to 306 to maintain theCBV closed such that no air is recirculated around the CAC andcompressor. Alternately, if surge conditions are present, the methodcontinues to 308 to determine if the engine is able to open the CBV. Forexample, if boost is not needed to deliver the torque demand, the enginemay be able to open the CBV. However, if increased boost is needed todeliver the demanded toque, the controller may not open the CBV. Inother examples, the compressor is surging, the CBV may openautomatically. If the CBV cannot be opened, the method continues to 306to maintain the CBV closed. However, if the CBV can be opened, themethod continues to 310 to open the CBV. In one example, opening the CBVmay include fully opening the CBV to a maximal percentage opening (ormaximal degree of opening). In another example, opening the CBV mayinclude partially opening the CBV to a percentage opening somewherebetween 0 and 100% open (e.g., between fully closed and fully open).

At 312, the method includes determining if surge has been mitigated. Forexample, if surge has not been mitigated or surge conditions are stillpresent, the method may continue to 314 to maintain the CBV open. In analternate example, the CBV may remain open until the pressure dropacross the compressor decreases to a threshold level. If surge has beenmitigated, the method continues to 316 to close the CBV.

FIG. 4 shows a method 400 for increasing airflow through the CAC topurge condensate from the CAC. Specifically, method 400 shows increasingairflow through the CAC responsive to condensate formation in the CAC.In an alternate embodiment, method 400 may be run periodically such thatairflow is increased through the CAC to decrease condensate at a setinterval. In one example, the set interval may be a duration of engineoperation or a distance of vehicle travel. Airflow through the CAC maybe increased by either operating the engine in VDE mode or opening theCBV while increasing boost to maintain torque. The decision to increaseairflow by operating in VDE mode or opening the CBV may be made based onengine operating conditions. Instructions for carrying out method 400may be stored in a memory of a controller (such as controller 12 shownin FIG. 2) and method 400 may be executed by the controller.

Method 400 begins at 402 by estimating and/or measuring engine operatingconditions. Engine operating conditions may include engine speed andload, ambient humidity, conditions of the CAC (e.g., temperature,pressure, and humidity), mass air flow (MAF, a position of the throttle,torque demand, EGR flow, VDE operation, compressor inlet pressure, etc.

At 404, the level of condensate at the CAC may be determined. This mayinclude retrieving details such as ambient air temperature, ambient airhumidity, CAC inlet and outlet charge air temperature, CAC inlet andoutlet charge air pressure, and air mass flow rate from a plurality ofsensors and determining the amount of condensate formed in the CAC basedon the retrieved data. Alternatively at 404, the method may includedetermining the propensity to form condensate. Said another way, at 404the method may include if condensate forming conditions are present. Forexample, if the CAC temperature is above a threshold, ambient humidityis above a threshold, and/or it is raining, condensate formation may belikely at the CAC.

In one example, at 406, and as further elaborated at the model of FIG.5, the rate of condensate formation within the CAC may be based onambient temperature, CAC outlet temperature, mass flow, EGR, andhumidity. In another example, at 408, a condensation formation value maybe mapped to CAC outlet temperature and a ratio of CAC pressure toambient pressure. In an alternate example, the condensation formationvalue may be mapped to

CAC outlet temperature and engine load. Engine load may be a function ofair mass, torque, accelerator pedal position, and throttle position, andthus may provide an indication of the air flow velocity through the CAC.For example, a moderate engine load combined with a relatively cool CACoutlet temperature may indicate a high condensation formation value, dueto the cool surfaces of the CAC and relatively low intake air flowvelocity. The map may further include a modifier for ambienttemperature.

At 410, the method includes determining if the condensate level at theCAC is higher than a threshold level. As such, the threshold level maycorrespond to an amount of condensate above which may cause unstablecombustion and/or engine misfire if blown out of the CAC and ingested atonce by the engine. In some examples, the threshold level may be reducedin order to dry out the CAC more frequently. As discussed above, inother examples, the method at 410 may include determining if condensateis forming or is likely to form within the CAC (based on CACtemperature, pressure, ambient temperature, ambient humidity, rainconditions, etc.). In this example, if condensate is forming or likelyto form, the method may continue on to 414. The method at 410 mayadditionally or alternately include determining if a duration has passedsince last purging condensate from the CAC. If the duration has passed,the method may continue to 414.

If condensate in the CAC is not greater than the threshold, the methodcontinues to 412 to maintain engine operation and not increase airflowthrough the CAC. Alternatively, if condensate formation is likely and/orif the condensate level in the CAC is greater than the threshold level,the method continues on to 414 to determine if it is possible to openthe CBV. For example, the method at 414 may include determining if surgeis expected or if MAP is greater than required to produce the torquedemand. In another example, the method at 414 may include determining ifopening the CBV temporarily to increase airflow through the CAC ispossible without degrading engine torque output. In some examples, themethod at 414 may override standard CBV control as shown at FIG. 3. Inthis way, opening the CBV responsive to CAC condensate may occur underdifferent conditions (e.g., no surge expected) than during normal engineoperation as shown in FIG. 3. If the controller determines the CBV maybe opened, the method continues on to 416 to open the CBV and increaseboost to increase airflow through the CAC. A method for increasingairflow through the CAC by opening the CBV is shown at FIG. 6, explainedfurther below. As described above and shown in FIG. 1, the CBV valve maybe positioned in a bypass passage around the CAC and compressor.

Alternatively at 414, if the controller is unable to open the CBV, themethod continues on to 418 to determine if the engine is currentlyoperating in VDE mode. If the engine is currently operating in VDE mode(e.g., with one or more cylinders deactivated), the method continues to420 to adjust VDE operation and increase boost to increase airflowthrough the CAC. A method for operating the engine in VDE mode toincrease airflow through the CAC is shown at FIG. 7, discussed furtherbelow.

If the engine is not currently operating in VDE mode, the methodcontinues to 422 to determine if the engine is able to temporarilyoperate in VDE mode (e.g., switch from non-VDE operation to VDEoperation). For example, the method at 422 may include determining iftorque demand is below a threshold such that VDE operation is possible.However, the threshold torque demand for operating in VDE mode due toCAC condensate may be higher than the threshold torque demand foroperating in VDE mode during standard engine operation (e.g., based onengine torque and load instead of based on CAC condensate). For example,the threshold for operating in VDE mode may be greater in the method at422 than in the method at 204. If the engine is able to temporarilyoperate in VDE mode, the method continues to 424 to switch the engine toVDE operation and increase boost in order to increase airflow throughthe CAC, as explained further below with regard to FIG. 7.

Alternately, if the engine is not able to operate in VDE mode, themethod continues to 426 to decrease CAC condensate using an alternatemethod. The method at 426 may additionally or alternately includewaiting until CBV opening or VDE operation is possible.

FIG. 5 illustrates a method 500 for estimating the amount of condensatestored within a CAC. Based on the amount (e.g., level) of condensate atthe CAC relative to a threshold value, an engine controller may increaseairflow through the CAC while maintain torque by operating in VDE modeor opening a CBV while increasing boost pressure, as discussed at FIG.4.

The method begins at 502 by determining the engine operating conditions.These may include, as elaborated previously at 402, ambient conditions,CAC conditions (inlet and outlet temperatures and pressures, flow ratethrough the CAC, etc.), mass air flow, MAP, EGR flow, engine speed andload, engine temperature, boost, etc. Next, at 504, the routinedetermines if the ambient humidity is known. In one example, the ambienthumidity may be known based on the output of a humidity sensor coupledto the engine. In another example, humidity may be inferred from adownstream UEGO sensor or obtained from infotronics (e.g., internetconnections, a vehicle navigation system, etc.) or a rain/wiper sensorsignal. If the humidity is not known (for example, if the engine doesnot include a humidity sensor), the humidity may be set to 100% at 506.However, if the humidity is known, the known humidity value, as providedby the humidity sensor, may be used as the humidity setting at 508.

The ambient temperature and humidity may be used to determine the dewpoint of the intake air, which may be further affected by the amount ofEGR in the intake air (e.g., EGR may have a different humidity andtemperature than the air from the atmosphere). The difference betweenthe dew point and the CAC outlet temperature indicates whethercondensation will form within the cooler, and the mass air flow mayaffect how much condensation actually accumulates within the cooler. At510, an algorithm may calculate the saturation vapor pressure at the CACoutlet as a function of the CAC outlet temperature and pressure. Thealgorithm then calculates the mass of water at this saturation vaporpressure at 512. Finally, the condensation formation rate at the CACoutlet is determined at 514 by subtracting the mass of water at thesaturation vapor pressure condition at the CAC outlet from the mass ofwater in the ambient air. In some examples, the method at 514 may firstdetermine a mass of water formation over time. Integrating this valuemay then give the mass of water within the CAC (e.g., condensateformation value). By determining the amount of time between condensatemeasurements at 516, method 500 may determine the amount of condensatewithin the CAC since a last measurement at 518. The current condensateamount in the CAC is calculated at 522 by adding the condensate valueestimated at 518 to the previous condensate value and then subtractingany condensate losses since the last routine (that is, an amount ofcondensate removed, for example, via purging routines) at 520.Condensate losses may be assumed to be zero if the CAC outlettemperature was above the dew point. Alternatively, at 520, the amountof condensate removed may be modeled or determined empirically as afunction of air mass and integrated down with each software task loop(that is, with each run of routine 500).

As such, the method of FIG. 5 may be used by the controller during theroutine of FIG. 4 to use a modeling method for estimating the amount ofcondensate at the CAC. In alternate embodiments, the engine controlsystem may use a mapping method to map the amount of condensate at theCAC to a CAC inlet/outlet temperature, an ambient humidity, and anengine load. For example, the values may be mapped and stored in alook-up table that is retrieved by the controller during the routine ofFIG. 4, and updated thereafter.

Turning now to FIG. 6, a method 600 is shown for increasing airflowthrough the CAC to purge condensate from the CAC by opening a CBV whileincreasing boost. As discussed above, the CBV may be arranged in abypass passage arranged between the intake passage downstream of the CACand the intake passage upstream of the compressor. Thus, opening the CBVmay recirculate air from downstream of the CAC to upstream of thecompressor, thereby increasing the amount of airflow through the CAC.Method 600 may continue from step 416 of method 400.

Method 600 begins at 602 by determining a desired degree of CBV opening(e.g., percentage opening between 0 and 100% open) based on CACcondensate. For example, as the condensate level in the CAC increases,the CBV may be opened by a greater degree (or opened to a largerpercentage opening). As such, the percentage opening of the CBV may bebased on an airflow increase required to blow the condensate storedwithin the CAC out of the CAC. At 604, the controller may open the CBVto the determined opening. As explained above, the method at 604 mayinclude fully opening the CBV such that the valve is 100% open oropening the CBV to a percentage opening somewhere between 0 and 100%.

At 606, the method includes increasing boost to maintain torque duringthe opening of the CBV. The methods at 604 and 606 may occursimultaneously such that the CBV opening and boost are both increased atthe same time. Increasing boost may include increasing rotation of thecompressor by increasing exhaust flow through the turbine coupled to thecompressor. In one example, increasing exhaust flow through the turbinemay include adjusting engine operation and/or adjusting a position of awastegate. In another example, increasing boost pressure may includeincreasing rotational output of the compressor by operating an electricmachine coupled to the compressor (e.g., operating an electricturbocharger). In yet another example, increasing boost may includeadjusting a position of a throttle positioned downstream of the CAC. Theamount of increase in boost level may be the amount of boost increaserequired to maintain the MAP to deliver the torque demand while openingthe CBV to the desired opening. As such, the increase in boost maycompensate for opening the CBV and thus boost may increase further asthe CBV opening increases.

At 608, the method includes determining if the condensate level in theCAC is below a threshold level and/or if a duration has passed. Forexample, after the condensate level has decreased back below thethreshold level, increasing airflow through the CAC may be stopped. Inanother example, the controller may increase airflow through the CAC fora duration. The duration may be based on the amount of condensate, atime required to purge condensate from the CAC, and/or a time that theengine may be operated with the CBV open. In some examples, thecontroller may shorten the duration if torque demand suddenly increasesabove a threshold (e.g., during a tip-in), thereby requiring increasedengine torque output. If the condensate level is not less than thethreshold level and/or the duration has not passed, the controller maymaintain the CBV open and the increased boost level at 610. However, ifthe CAC condensate level is less than the threshold and/or the durationhas passed, the method continues to 612 to return to normal CBVoperation (as shown at FIG. 3) and return boost to a requested level(based on the torque demand). The method at 612 may include closing theCBV or adjusting the position of the CBV based on engine operatingconditions determined in the method shown at FIG. 3.

FIG. 7 shows a method for increasing airflow through the CAC to purgecondensate from the CAC by deactivating one or more engine cylinderswhile increasing boost. Deactivating one or more engine cylinders mayalso be referred to herein as operating in a VDE mode. During cylinderdeactivation, or VDE mode, fueling may be disabled to the one or moredeactivated engine cylinders while the intake and exhaust valves remainoperational. As such, during cylinder deactivation, air may continue topump through the deactivated cylinders, thereby increasing airflowthrough the CAC. As more cylinders are deactivated, the amount ofairflow through the CAC may increase further. Method 700 may continuefrom step 420 and/or step 424 of method 400.

Method 700 begins at 702 by determining a number of engine cylinders todeactivate based on CAC condensate. For example, as the condensate levelin the CAC increases, the controller may deactivate a larger number ofcylinders. As such, the number of deactivated cylinders may be based onan airflow increase required to blow the condensate stored within theCAC out of the CAC. In another example, the number of deactivatedcylinders may also be based on current VDE operation (if the engine wasalready in VDE mode), and/or the engine torque demand.

At 704, the controller deactivates the determined number of cylinders byshutting off fueling to those cylinders. At 706, the method includesincreasing boost to increase MAP and deliver the demanded torque withthe active cylinders. The method at 706 may also include adjusting thewastegate and/or throttle to deliver torque during VDE operation. Themethods at 704 and 706 may occur simultaneously such that the VDEoperation and boost increase occur at the same time. As discussed above,increasing boost may include increasing rotation of the compressor byincreasing exhaust flow through the turbine. Increasing exhaust flowthrough the turbine to increase boost may include adjusting one or moreof engine operation, a wastegate, or an electric machine such as anelectric turbocharger.

At 708, the method includes determining if the condensate level in theCAC is below a threshold level and/or if a duration has passed. Forexample, after the condensate level has decreased back below thethreshold level, increasing airflow through the CAC may be stopped. Inanother example, the controller may increase airflow through the CAC fora duration. The duration may be based on the amount of condensate, atime required to purge condensate from the CAC, and/or a time that theengine may be operated in VDE mode with the one or more cylindersdeactivated. In some examples, the controller may shorten the durationif torque demand suddenly increases above a threshold (e.g., during atip-in), thereby requiring increased engine torque output. If thecondensate level is not less than the threshold level and/or theduration has not passed, the controller may maintain VDE operation andthe increased boost level at 710. However, if the CAC condensate levelis less than the threshold and/or the duration has passed, the methodcontinues to 712 to reactivate the deactivated cylinders and/or returnto normal VDE operation (as shown at FIG. 2) and return boost to arequested level (based on the torque demand).

Turning now to FIG. 8, a graphical example of adjusting engineparameters to increase airflow through the CAC responsive to CACcondensate is shown. Specifically, graph 800 shows changes in CACcondensate level at plot 802, changes in airflow through the CAC at plot804, changes in CBV opening at plot 806, changes in VDE operation atplot 808, changes in boost level at plot 810, and changes in torque atplot 812.

Prior to time t1, the CBV may be closed and the engine may not beoperating in VDE mode (e.g., all cylinders are active). CAC airflow maybe at a fairly low and steady level while CAC condensate level isincreasing (plot 802). At time t1, the condensate level in the CACincreases above a threshold level, T1. In response, the controller opensthe CBV to increase airflow through the CAC (plot 806). The controllermay open the CBV since torque is below a threshold and opening the CBVmay not degrade engine torque output. In an alternate embodiment, thecontroller may operate the engine in VDE mode at time t1 instead ofopening the CBV. Between time t1 and time t2, the CBV is opened to apercentage opening somewhere between 0% (fully closed) and 100% open(fully open). The percentage opening of the CBV is based on the CACcondensate level. For example, the controller may open the CBV to agreater opening percentage as the amount of condensate above thethreshold level T1 increases. Also at time t1, the controller increasesboost (plot 810) in order to maintain torque (plot 812) during theopening of the CBV and increasing airflow through the CAC. As CACairflow increases, the condensate level in the CAC decreases (plot 802).

At time t2, the CAC condensate level decreases below the threshold levelT1 (plot 802). As a result, the controller closes the CBV (plot 806) andreturns CBV operation to standard CBV operation based on engineoperating conditions and not based on CAC condensate. Boost pressuredecreases to return boost to a level required to produce the torquedemand (plot 810). Between time t2 and time t3 torque demand maydecrease and the engine may switch into a VDE mode by deactivating oneor more engine cylinders (plot 808). At time t3, the CAC condensatelevel increases above the threshold level T1. As a result of the CACcondensate level increasing above the threshold and the engine alreadyoperating in VDE mode, the controller may adjust VDE operation in orderto increase airflow through the CAC (plot 804) and purge condensate fromthe CAC and into the engine intake. For example, at time t3, the enginemay be unable to open the CBV to increase airflow since the engine isalready operating in VDE mode. At time t3, the controller may adjust VDEoperation to further increase CAC airflow. This may include deactivatingadditional cylinders based on the condensate level during the VDEoperation. Also at time t3, the controller further increases boost (plot810) in order to increase MAP to deliver the torque with the remainingactive cylinders.

At time t4, a tip-in occurs and causes torque demand to increase above athreshold level (plot 812). In response to the increase in torque demandover the threshold, the controller switches from VDE mode to non-VDEmode by reactivating the deactivated engine cylinders (plot 808). Boostmay remain at a higher level in order to deliver the increased torquedemand with all the activated cylinders. After time t4, the controllermay not operate in VDE mode or open the CBV even though the CACcondensate level is above the threshold level T1 since torque demandremains above the threshold torque level.

As shown at time t1 in FIG. 8, a method for an engine includes during afirst condition, increasing airflow through a charge air cooler (CAC) byopening a compressor bypass valve while increasing boost pressure inresponse to a condensate level in the CAC increasing above a threshold.The first condition includes one or more of a surge condition or amanifold pressure greater than required to produce a torque demand.Additionally, as shown at time t2, the method includes stoppingincreasing airflow through the CAC by closing the CBV responsive to theCAC condensate level decreasing below the threshold level.

The method further includes, during a second condition (as shown at timet3), increasing airflow through the CAC by selectively deactivating oneor more cylinders of the engine while increasing boost pressure inresponse to the condensate level in the CAC increasing above thethreshold. The second condition includes when the CBV is unable to beopened and one or more of the engine is already operating with one ormore cylinders deactivated or engine torque demand is below a thresholdfor temporarily operating with one or more cylinders deactivated.

The method further comprises during a third condition (as shown aftertime t4), not increasing airflow through the CAC, maintaining the CBVclosed, and maintaining all cylinders active even when a condensatelevel in the CAC is above the threshold level, the third conditionincluding when the CBV is unable to be opened and the engine is unableto deactivate one or more cylinders due to engine operating conditionsincluding torque demand over a threshold. Additionally, as shown at timet4, the method includes stopping increasing airflow through the CAC byreactivating the one or more deactivated cylinders responsive to thetorque demand increasing over a threshold.

In this way, condensate may be periodically or opportunistically purgedfrom the CAC by increasing airflow through the CAC. An engine controllermay increase airflow through the CAC by either operating the engine in aVDE mode or opening a CBV valve arranged in a bypass passage around theCAC and the compressor. At the same time, the controller may increaseboost in order to maintain torque during the increasing airflow throughthe CAC. A technical effect of decreasing an amount of condensate storedwithin the CAC is achieved by periodically and/or opportunisticallyincreasing airflow through the CAC in this way. By reducing the amountof condensate within the CAC, engine misfire and/or unstable combustiondue to ingestion of large amounts of condensate may be reduced.

Note that the example control and estimation routines included hereincan be used with various engine and/or vehicle system configurations.The control methods and routines disclosed herein may be stored asexecutable instructions in non-transitory memory. The specific routinesdescribed herein may represent one or more of any number of processingstrategies such as event-driven, interrupt-driven, multi-tasking,multi-threading, and the like. As such, various actions, operations,and/or functions illustrated may be performed in the sequenceillustrated, in parallel, or in some cases omitted. Likewise, the orderof processing is not necessarily required to achieve the features andadvantages of the example embodiments described herein, but is providedfor ease of illustration and description. One or more of the illustratedactions, operations and/or functions may be repeatedly performeddepending on the particular strategy being used. Further, the describedactions, operations and/or functions may graphically represent code tobe programmed into non-transitory memory of the computer readablestorage medium in the engine control system.

It will be appreciated that the configurations and routines disclosedherein are exemplary in nature, and that these specific embodiments arenot to be considered in a limiting sense, because numerous variationsare possible. For example, the above technology can be applied to V-6,I-4, I-6, V-12, opposed 4, and other engine types. The subject matter ofthe present disclosure includes all novel and non-obvious combinationsand sub-combinations of the various systems and configurations, andother features, functions, and/or properties disclosed herein.

The following claims particularly point out certain combinations andsub-combinations regarded as novel and non-obvious. These claims mayrefer to “an” element or “a first” element or the equivalent thereof.Such claims should be understood to include incorporation of one or moresuch elements, neither requiring nor excluding two or more suchelements. Other combinations and sub-combinations of the disclosedfeatures, functions, elements, and/or properties may be claimed throughamendment of the present claims or through presentation of new claims inthis or a related application. Such claims, whether broader, narrower,equal, or different in scope to the original claims, also are regardedas included within the subject matter of the present disclosure.

1. A method for an engine, comprising: transiently increasing airflowthrough a charge air cooler (CAC) of the engine by opening a compressorbypass valve; while maintaining engine torque by increasing boostpressure by closing a turbocharger wastegate.
 2. The method of claim 1,wherein the transiently increasing airflow through the CAC is performedperiodically when condensate forming conditions are present, thecondensate forming conditions including one or more of an ambienthumidity over a threshold humidity, a CAC temperature below a thresholdtemperature, and an ambient temperature below a threshold temperature.3. The method of claim 1, wherein the transiently increasing airflowthrough the CAC is responsive to one or more of a condensate level or acondensate accumulation rate within the CAC over a threshold.
 4. Themethod of claim 1, further comprising in another condition, transientlyincreasing airflow through the CAC by operating in the VDE mode when thecompressor bypass valve cannot be opened.
 5. The method of claim 1,wherein transiently increasing airflow through the CAC by opening thecompressor bypass valve does not include operating in VDE mode.
 6. Themethod of claim 1, wherein opening the compressor bypass valve (CBV) toincrease airflow through the CAC includes opening the CBV to adetermined percentage opening, the percentage opening determined basedon condensate level in the CAC and further increasing with increasingcondensate level in the CAC.
 7. The method of claim 1, furthercomprising stopping increasing airflow through the CAC by closing theCBV responsive to a determined condensate level in the CAC decreasingbelow a threshold.
 8. The method of claim 1, further comprising stoppingincreasing airflow through the CAC by closing the CBV responsive to atorque demand over a threshold.
 9. The method of claim 1, wherein thecompressor bypass valve is positioned in a bypass passage positionedbetween an intake passage downstream of the CAC and the intake passageupstream of a compressor of the engine.
 10. A method for an enginecomprising: during a first condition, increasing airflow through acharge air cooler (CAC) by opening a compressor bypass valve (CBV) whileincreasing boost pressure in response to a condensate level in the CACincreasing above a threshold; and during a second condition, increasingairflow through the CAC by selectively deactivating one or morecylinders of the engine while increasing boost pressure in response tothe condensate level in the CAC increasing above the threshold;
 11. Themethod of claim 10, wherein the first condition includes one or more ofa surge condition or a manifold pressure greater than required toproduce a torque demand.
 12. The method of claim 10, wherein the secondcondition includes when the CBV is unable to be opened and one or moreof the engine is already operating with one or more cylindersdeactivated or engine torque demand is below a threshold for temporarilyoperating with one or more cylinders deactivated.
 13. The method ofclaim 10, further comprising during a third condition, not increasingairflow through the CAC, maintaining the CBV closed, and maintaining allcylinders active even when the condensate level in the CAC is above thethreshold, the third condition including when the CBV is unable to beopened and the engine is unable to deactivate one or more cylinders dueto engine operating conditions including torque demand over a threshold.14. The method of claim 10, further comprising stopping increasingairflow through the CAC by one or more of reactivating the one or moredeactivated cylinders or closing the CBV responsive to one or more ofthe condensate level in the CAC decreasing below the threshold or atorque demand over a threshold.
 15. A system for an engine, comprising:an intake passage including a throttle; a turbocharger including acompressor at least partially driven by an exhaust-driven turbine; acharge air cooler (CAC) positioned upstream of the throttle anddownstream of the compressor; a compressor bypass valve (CBV) positionedin a bypass passage coupled between the intake passage downstream of theCAC and the intake passage upstream of the compressor; and a controllerwith computer readable instructions for: transiently increasing airflowthrough the CAC by opening the CBV responsive to a determined level ofcondensate formation in the CAC; and maintaining engine torque byincreasing boost pressure.
 16. The system of claim 15, furthercomprising an electric machine coupled to the turbocharger, the electricmachine providing rotative power to the compressor to increase boostpressure, wherein the engine is a variable displacement engine (VDE).